U.S. patent number 10,145,125 [Application Number 14/964,561] was granted by the patent office on 2018-12-04 for cove base molding systems and methods.
The grantee listed for this patent is Christopher J. O'Brien. Invention is credited to Christopher J. O'Brien.
United States Patent |
10,145,125 |
O'Brien |
December 4, 2018 |
Cove base molding systems and methods
Abstract
The cove base molding strip includes a body including a planar
portion having a front surface and a rear surface and a curved
portion having a concave surface continuous with the front surface
and a convex surface continuous with the rear surface. The rear
surface includes at least a first channel. A cove anchor projects
from the convex surface, and the intersection of the front surface
and the rear surface define a rounded tip that projects from the
planar portion.
Inventors: |
O'Brien; Christopher J. (Las
Vegas, NV) |
Applicant: |
Name |
City |
State |
Country |
Type |
O'Brien; Christopher J. |
Las Vegas |
NV |
US |
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Family
ID: |
56093821 |
Appl.
No.: |
14/964,561 |
Filed: |
December 9, 2015 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20160160510 A1 |
Jun 9, 2016 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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62089670 |
Dec 9, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04F
19/0477 (20130101); E04F 2019/0422 (20130101) |
Current International
Class: |
E04F
19/04 (20060101) |
Field of
Search: |
;52/203,204.53,204.54,204.62,208,716.2,717.03,717.05 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Other References
The Engineering ToolBox, "Temperature Expansion Coefficients for
some common Piping Materials,"
http://www.engineeringtoolbox.com/pipes-temperature-expansion-coefficient-
s-d_48.html (last accessed on May 25, 2016). cited by examiner
.
Machine translation of Foreign reference DE 29711019U1, obtained
from
http://translationportal.epo.org/emtp/translate/?ACTION=description-retri-
eval&COUNTRY=DE&ENGINE=google&FORMAT=docdb&KIND=U1&LOCALE=en_EP&NUMBER=297-
11019&OPS=ops.epo.org/3.2&SRCLANG=de&TRGLANG=en (last
accessed on Apr. 25, 2017). cited by examiner.
|
Primary Examiner: Adamos; Theodore V
Attorney, Agent or Firm: Richards Patent Law P.C.
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of priority to U.S. Provisional
Application No. 62/089,670 filed on Dec. 9, 2014, the disclosure of
which is incorporated herein by reference.
Claims
I claim:
1. A cove base molding strip positioned adjacent to a floor/wall
junction, comprising: a body including a planar portion having a
front surface and a rear surface, a curved portion having a concave
surface continuous with the front surface and a convex surface
continuous with the rear surface, and a planar bottom surface
bridging the concave surface and convex surface at a lower end of
the body; wherein the body has a body height and the planar bottom
surface has a planar bottom surface width, and wherein the ratio of
the body height to the planar bottom surface width is about 8;
wherein the rear surface includes at least a first channel and a
second channel recessed within the planar portion at opposite ends
thereof; and first and second beads of adhesive applied to the
first and second channels, respectively; wherein a cove anchor
projects from the convex surface; and wherein an intersection of
the front surface and the rear surface define a rounded tip that
projects from the planar portion.
2. The base molding strip of claim 1, wherein the body comprises a
polymeric material.
3. The base molding strip of claim 1, wherein the rounded tip
projects rearward of the rear surface.
4. The base molding strip of claim 1, wherein the front surface and
the rear surface define the rounded tip at an upper end of the
body, and wherein the planar bottom surface bridges the convex
surface and the concave surface at a lower end of the body.
5. The base molding strip of claim 1, wherein the first channel
includes an opening in the rear surface and a volume within the
body, wherein the opening has an opening width and the volume has a
volume width, and wherein the first channel is partially enclosed
so that the opening width is less than the volume width.
6. The base molding strip of claim 5, wherein the first channel has
a dovetail shape in cross section.
7. The base molding strip of claim 1, wherein each of the first
channel and the second channel has a dovetail shape in cross
section.
8. The base molding strip of claim 1, wherein the cove anchor
projects from the convex surface at an angle of about 45 degrees
relative to the planar portion.
9. The base molding strip of claim 8, wherein the cove anchor
includes a head portion including first and second planar
surfaces.
10. The base molding strip of claim 1, further comprising an
adhesive.
11. The base molding strip of claim 1, wherein the body comprises a
material that is not flammable.
12. The cove base molding strip of claim 1, wherein the planar
bottom surface width is at least about 0.5 in.
13. A method for installing a base molding strip to a junction of a
wall and a floor comprising: providing a base molding strip
comprising: a body including a planar portion having a front
surface and a rear surface and a curved portion having a concave
surface continuous with the front surface and a convex surface
continuous with the rear surface; wherein the rear surface includes
at least a first channel and a second channel recessed within the
planar portion at opposite ends thereof; wherein a cove anchor
projects from the convex surface; and wherein the intersection of
the front surface and the rear surface define a rounded tip that
projects from the planar portion; and applying a first adhesive
bead within the first channel; applying a second adhesive bead
within the second channel; applying a third adhesive bead to the
wall/floor junction; positioning the base molding strip on the wall
so that the rear surface of the body directly contacts the wall
while the first adhesive bead within the first channel contacts the
wall and the anchor contacts the second adhesive bead; and
positioning the cove anchor in contact with the junction of the
wall and the floor.
14. The method of claim 13, further comprising the step of applying
the third adhesive bead to the wall prior to the step of
positioning the base molding on the wall.
15. The method of claim 13, further comprising the step of applying
pressure to the base molding strip such that the rounded tip forms
a seal against the wall.
16. The method of claim 13, wherein the providing step comprises
providing first and second base molding strips, each strip
including vertical ends, and wherein the method further comprises
the step of applying a fourth adhesive bead to a vertical end of
the first base molding strip and securing the vertical end of the
first base molding strip to the vertical end of the second base
molding strip.
Description
BACKGROUND OF THE INVENTION
The present subject matter relates generally to polymeric,
pre-formed cove base molding systems and methods. More
specifically, the present invention relates to a polymeric cove
base molding system utilizing a cove base molding strip including
channels and a cove anchor to improve water tightness and bonding
strength.
Cove base molding is installed onto the wall/floor junction and
includes a concave profile at a lower portion that extends onto the
floor to provide an aesthetic and protective finish to the
junction. It is typically made of vinyl or wood, which helps the
cove base molding to provide some protection of the wall from
damage. To install cove base molding, a user typically uses a
simple cutting tool, an adhesive, and possibly caulk. The user cuts
the desired length of base molding using the cutting tool, applies
adhesive to the back of the base molding, and firmly presses it
onto the wall. Caulk may be used to fill in any gaps between the
top of the molding and the wall.
Existing cove base molding technology is flammable, is not impact
resistant, and is a poor water barrier. When fire tested,
conventional cove base molding catches fire, creating a hazard to
the consumer. Under tensile and impact testing, the material
deforms and can be penetrated. Traditional cove base molding also
fails to create a fully watertight installation, creating a porous
structure at the wall/floor junction that can harbor and promote
the growth of mold and mildew hazards. These cove base moldings
have flat back surfaces that are adhered to wall and floor. The
flat design results in a relatively low bond strength of the
adhesive to the cove base molding and substrate, increasing the
potential for moisture intrusion between the wall and the cover
base molding.
An alternative to cove base molding is traditional wood baseboard
material. When installing wood baseboards, a user must use multiple
tools to cut baseboards for corners. Angles must be measured and
cut precisely so that the baseboards fit together and form a flush
connection. In contrast, polymeric cove base molding is less
expensive and easier to install. Unlike the installation of wood
baseboards, the installation of polymeric cove base molding does
not require a high level of precision because the cove base molding
is flexible and easily cut.
Accordingly, there is a need for a cove base molding system that
provides a durable and complete moisture barrier and is easy to
install, as described herein.
BRIEF SUMMARY OF THE INVENTION
To meet the needs described above and others, the cove base molding
systems and methods of the present disclosure utilize a polymeric
cove base molding strip that helps to provide a more complete
moisture barrier at the wall/floor junction. A body of the cove
base molding strip has a planar portion that includes a front
surface and a rear surface and a curved portion having a concave
surface continuous with the front surface and a convex surface
continuous with the rear surface. The rear surface includes one or
more channels, and the front and rear surfaces intersect to define
a rounded tip that projects rearwardly in the resting position. A
cove anchor projects from the convex surface into the wall/floor
junction in the installed position.
The channels, the cove anchor, and the rounded tip work together to
provide the moisture barrier when installed. The channels form a
mechanical lock by increasing the contact area of the adhesive to
the cove base molding as well as providing a partially enclosed
structure to confine the adhesive, thereby increasing the bond
strength of the adhesive to the cove base molding strip. The cove
anchor provides an additional moisture barrier and bond strength
when adhered to the wall/floor junction by means of an adhesive.
The rounded tip helps to create a seal at the wall when the strip
is installed. Therefore, the polymeric base molding system creates
a superior bond adhesion to the floor and the wall, provides a
complete moisture barrier, and prevents moisture intrusion and
bacterial growth. While all of these features improve the water
tightness of the system, the system may include more or fewer
features depending on the requirements of the environment in which
it is installed.
To install the cove base molding, the user cuts the desired length
of the cove base molding strip if necessary (which may come in
sections of varying sizes), applies a bead of adhesive to the
channels on the rear surface, applies a bead of adhesive to the
wall/floor junction, and presses the molding firmly into the
desired location. In contrast to the traditional cove base molding
having a flat back, the channels in the rear surface as well as the
cove anchor of the cove base molding strips of the present
application provide partially enclosed surfaces with greater
surface area for the adhesive to contact and locking the adhesive
within the cove base molding strip, increasing the adhesive bond
and thereby ensuring that the cove base molding stays firmly in
place while also creating a waterproof barrier. Because the
material of the molding can expand, it will not crack and/or
separate with time like traditional systems might.
In one embodiment, a cove base molding strip of the present
application comprises a body including a planar portion having a
front surface and a rear surface and a curved portion having a
concave surface continuous with the front surface and a convex
surface continuous with the rear surface. The rear surface includes
at least a first channel. A cove anchor projects from the convex
surface, and the intersection of the front surface and the rear
surface define a rounded tip that projects from the planar
portion.
In some embodiments, the rounded tip projects rearward of the rear
surface. In other embodiments, the front surface and the rear
surface define the rounded tip at an upper end of the body, and
wherein a planar bottom surface bridges the concave surface and the
convex at a lower end of the body.
In still further embodiments, the rear surface includes a second
channel spaced from the first channel, and each of the first
channel and the second channel has a dovetail shape.
In an addition embodiment, the base molding strip includes a cove
anchor projects from the convex surface at an angle of about 45
degrees relative to the planar portion. In a further embodiment,
the cove anchor includes a head portion including first and second
planar surfaces.
In further embodiments, the body comprises a material having an
expansion coefficient of between about 25 and about 55, preferably
between about 28 and about 50.4. For example, the material may be a
polymer.
In still a further embodiment, a method of the present application
for installing a base molding strip to a wall/floor junction
includes the step of providing a base molding strip. The strip
comprises a body including a planar portion having a front surface
and a rear surface and a curved portion having a concave surface
continuous with the front surface and a convex surface continuous
with the rear surface. The rear surface includes at least a first
channel. A cove anchor projects from the convex surface, and the
intersection of the front surface and the rear surface define a
rounded tip that projects from the planar portion. The method
further includes the steps of applying a first adhesive bead to the
one or more channels, applying a second adhesive bead to the
wall/floor junction, and positioning the base molding on the wall
so that the first adhesive bead contacts the wall and the anchor
contacts the second adhesive bead.
In a further embodiment, the method comprises the step of applying
adhesive to the wall prior to the step of positioning the base
molding on the wall. Further, the method may also include the step
of applying pressure to the base molding strip such that the
rounded tip forms a seal against the wall.
In an additional embodiment, the providing step comprises providing
first and second base molding strips, each strip including vertical
ends. The method further comprises the step of applying a third
adhesive bead to a vertical end of the first base molding strip and
securing the vertical end of the first base molding strip to the
vertical end of the second base molding strip.
An object of the invention is to provide a cove base molding with a
complete moisture barrier, thus preventing moisture intrusion and
bacterial growth.
Yet another advantage of the invention is that the cove base
molding system can be installed easily and quickly.
A further advantage of the invention is that the cove base molding
system utilizes mitered base molding strips to form corners, rather
than requiring a pre-fabricated angled corner.
Another advantage of the invention is that the cove base molding
strip comprises a material that is not flammable and has increased
strength to resist impacts and tension.
Another advantage of the invention is that it has an expansion
coefficient similar to epoxy to eliminate cracking and
separation.
Additional objects, advantages and novel features of the examples
will be set forth in part in the description which follows, and in
part will become apparent to those skilled in the art upon
examination of the following description and the accompanying
drawings or may be learned by production or operation of the
examples. The objects and advantages of the concepts may be
realized and attained by means of the methodologies,
instrumentalities and combinations particularly pointed out in the
appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawing figures depict one or more implementations in accord
with the present concepts, by way of example only, not by way of
limitations. In the figures, like reference numerals refer to the
same or similar elements.
FIG. 1 is an elevational view of a cross section of a cove base
molding strip in the resting position.
FIG. 1A is an elevational view identical to FIG. 1 illustrating
sample dimensions for the cove base molding strip.
FIG. 2 is an elevational view of a cross section of the cove base
molding strip of FIG. 1 in the installed position.
FIG. 3 is a perspective, cross section view of the cove base
molding system including the cove base molding strip of FIG. 1 in
the installed position.
DETAILED DESCRIPTION
The cove base molding systems 10 and methods of the present
application utilize a cove base molding strip 12 that includes a
body 14 having a planar portion 16 and a curved portion 18 as shown
in FIG. 1. Referring to FIG. 2, the planar portion 16 is secured to
a lower portion 20 of a wall 22 and the curved portion 18, referred
to as the cove, extends onto the floor 24 so that it covers a
wall/floor junction 26 when the cove base molding system 10 is
installed.
Shown in FIGS. 1 and 2, the planar portion 16 includes a front
surface 28 and a rear surface 30 that intersect to define a rounded
or radiused tip 32 at an upper end 34 of the body 14. In the
illustrated embodiment, the rounded tip 32 projects rearward of the
rear surface 30. The rounded tip 32 extends beyond the rear surface
30 in the resting position so that movement of the rear surface 30
into the installed position causes the rounded tip 32 to deform
slightly which, when constructed from an elastic material, causes
the rounded tip 32 to press firmly against the wall 22, creating a
seal 36 that acts as a moisture barrier. The curved shape of the
rounded tip 32 provides a smaller surface area of the upper end 34
of the cove base molding strip 12, thereby minimizing the amount of
dust that can accumulate along the top of the cove base molding
strip 12. The seal 36 created by the rounded tip 32 and the wall 22
also eliminates the need for caulking this junction.
The rear surface 30 of the planar portion 14 includes one or more
channels 38 that receive a bead of adhesive 40 during installation
as shown in FIG. 2. Each channel 38 provides additional surface
area to which the adhesive material 40 bonds. Further, each channel
38 may be partially enclosed (for example, with a narrowing near
the opening of the channel 38 at the rear surface 30) so that an
opening of the channel has a width that is less than a width of the
body of the channel 38. Accordingly, once cured, the adhesive 40 is
locked into the channel 38, thereby strengthening the bond between
the cove base molding strip 12, the adhesive 40, and the wall
22--the cove base molding strip 12 can not be released from the
wall 22 because the cured adhesive 40 in the channel 38 can not be
squeezed through the narrowed opening of the channel 38. In the
illustrated embodiment, the cove base molding strip 12 includes two
spaced channels 38 that extend along the length of the strip 12. In
some embodiments, each channel 38 has a dovetail shape, although
the shape and size of the channel 38 may vary depending on the
molding process and materials used, the mechanical properties of
the material, and other related factors.
The curved portion 18 includes a concave surface 42 continuous with
the front surface 28 and a convex surface 44 continuous with the
rear surface 30. A planar bottom surface 46 bridges the concave
surface 42 and the convex surface 44 at a lower end 48 of the body
14. When installed, movement from the resting position to the
installed position results in the application of pressure to the
planar bottom surface 46, creating a seal 50 that acts as a
moisture barrier.
The cove base molding strip 12 also includes a cove anchor 52 that
extends into the wall/floor junction 26 when installed to properly
position the cove base molding strip 12 on the wall 22 and to
provide an additional moisture barrier. In the illustrated
embodiment, the cove anchor 52 extends from the convex surface 44
of the cove base molding strip 12 at an angle of about 45 degrees
relative to the rear surface 30. A head portion 54 of the cove
anchor contacts the wall/floor junction 26 as seen in FIG. 2. In
the illustrated embodiment, the head portion 54 includes first and
second planar surfaces 56a, 56b that correspond to the wall 22 and
the floor 24, respectively. The shape of the head portion 54 may
include more or fewer surfaces of any size and shape as desired. In
some embodiments, the cove anchor 52 may have a consistent cross
section throughout the length of the cove base molding strip 12. In
other embodiments, the cove base molding strip 12 may include one
or more cove anchors 52 spaced apart from one another. In the
resting position shown in FIG. 1, the cove anchor 52 is spaced
apart from the wall/floor junction 26. During installation, the
cove anchor 52 is secured to the floor/wall junction 26 by an
adhesive 58 as shown in FIG. 2.
The cove base molding system 10 may include a plurality of cove
base molding strips 12 positioned adjacent to one another as shown
in FIG. 3. In one embodiment, the length of each strip 12 is 48
inches, although the length may vary. Adjacent cove base molding
strips 12 may be joined together using an adhesive (not visible)
along the vertical ends 60 of each strip 12 to form a vertical
joint 62. The user may install the cove base molding system 10
around a corner using cove base molding strips 12 with mitered
vertical ends (not shown).
In an example embodiment, the cove base molding strip 12 has the
dimensions noted in the following table and as seen in FIG. 1A. It
should be noted that the dimensions in the following table are
exemplary only and not limiting.
TABLE-US-00001 TABLE 1 Nominal Dimension (millimeters unless FIG.
1A otherwise noted) A 0.025 B 0.470 C 4.000 D 0.025 (radius of
curvature) E 0.515 F 1.250 G 0.281 H 90 degrees J 0.300 K 0.200 L
0.070 M 0.207
The cove base molding strip 12 may be made of any suitable material
that has an expansion coefficient similar to that of epoxy in order
to eliminate cracking and separation. In a preferred embodiment,
the expansion coefficient is between about 28 and about 50.4 An
example material is a polymer, although any other suitable material
or combinations of materials may be used. The adhesive material 40,
58 used to adhere the cove base molding strip 12 to the wall 22 and
the floor 24 may be a two component, fast drying adhesive, or any
other suitable adhesive. The adhesive material (not visible) used
to join two adjacent cove base molding strips 12 as described below
may be a single component, low viscosity, cyanoacrylate adhesive,
although any other suitable adhesive may be used.
To install the cove base molding system 10, the user determines the
number of cove base molding strips 12 needed. If more than one
strip 12 is necessary, the user may join adjacent strips 12 prior
to installation or during installation. For example, the user may
apply an adhesive to the vertical ends 60 of adjacent first and
second strips 12 to form a continuous strip, and then mount the
continuous strip to the wall 22. Alternatively, the user may apply
the first strip 12 to the wall 22 according to the following
description, then apply an adhesive to the vertical end 60 of the
first strip 12 and/or the vertical end 60 of the second strip 12,
and then mount the second strip 12 to the wall immediately adjacent
to the first strip 12 to form the joint 62. In either embodiment,
the cove base molding system 10 may include pins or other fastening
mechanisms that bridge the channels 38 of adjacent cove base
molding strips 12 to join adjacent strips 12.
Prior to mounting each cove base molding strip 12 (or continuous
strip) to the wall 22, the user applies an adhesive bead 40 to the
one or more channels 38 on the rear surface 30 of the base molding
strip 12 and an adhesive bead 58 to the wall/floor junction 26. The
user may optionally apply a bead of adhesive to the wall 22 as
well. The user then positions the base molding strip 12 on the wall
22 so that the adhesive bead 40 on the one or more channels 38
contacts the wall 22 and the cove anchor 52 contacts the adhesive
bead 58 on the wall/floor junction 26. The user applies pressure
and holds the strip 12 in place as the adhesives 40, 58 dries. If
any gaps are formed between the upper end 34 of the strip 12 and
the wall 22, the user may insert adhesive 40, 58 into the gap and
apply pressure until the adhesive 40, 58 dries in order to close
the gap. The user may also apply additional adhesive 40, 58 atop
vertical joints 62 to strengthen the joint 62.
It should be noted that various changes and modifications to the
presently preferred embodiments described herein will be apparent
to those skilled in the art. Such changes and modifications may be
made without departing from the spirit and scope of the present
invention and without diminishing its attendant advantages.
* * * * *
References